BALL LOCK Â® MOUNTING SYSTEM QUICK CHANGE ... - Jergens Inc.

www.jergensinc.com 

BALL QUICK LOCK ® 

CHANGE MOUNTING FIXTURING SYSTEM 

1 

Quick Change Fixturing 

Ball Lock ® Mounting System (Inch) 

Ball Lock ® for Rotary Indexers..... 1.16-1.17 

Ball Lock ® Accessories........................ 1.20 

Commonly Asked Questions 

About the Ball Lock ® 

Mounting System ...................... 1.4-1.5 

Fast Acting Ball Lock ® Shanks............. 1.20 

Fixture Kits for HAAS.......................... 1.14 

Fixture Plates........................................ 1.9 

Fixture Plates for 

Multi-Purpose Subplates................... 1.7 

Fixture Plates for Tooling Columns..... 1.12 

Jigsaw Interlocking Plates.................... 1.7 

Liners.................................................. 1.19 

Modular Grid Fixture Plates.................. 1.7 

Multi-Purpose Subplates...................... 1.6 

Quick Change Kits.............................. 1.13 

Receiver Bushings.............................. 1.19 

Repair Kits.......................................... 1.18 

Set-Up Reduction Worksheet............. 1.15 

Shanks................................................ 1.18 

Subplates.............................................. 1.8 

Subplates for Tooling Columns........... 1.12 

Tooling Columns, 4 sided................... 1.11 

Tooling Columns, T-Columns.............. 1.10 

Ball Lock ® Mounting System (Metric) 

Ball Lock ® for Rotary Indexers...... 1.29-1.30 

Ball Lock ® Accessories........................ 1.33 

Fast Acting Ball Lock ® Shanks............. 1.33 

Fixture Plates...................................... 1.24 

Fixture Plates for 

Multi-Purpose Subplates................. 1.22 

Fixture Plates for Tooling Columns..... 1.28 

Jigsaw Interlocking Plates.................. 1.22 

Liners.................................................. 1.32 

Modular Grid Fixture Plates................ 1.22 

Multi-Purpose Subplates.................... 1.21 

Quick Change Kits.............................. 1.25 

Receiver Bushings.............................. 1.32 

Repair Kits.......................................... 1.31 

Shanks................................................ 1.31 

Subplates............................................ 1.23 

Subplates for Tooling Columns........... 1.28 

Tooling Columns, 4 sided................... 1.27 

Tooling Columns, T-Columns.............. 1.26 

Lite Lock Mounting Systems 

Lite Lock Mounting System........ 1.34-1.35 

Zero Point Mounting System 

Clamping Bracket............................... 1.48 

Pull Studs & Engagement 

Screws..................................... 1.42-1.43 

Clamping Plates................................. 1.41 

Clamping and Positioning................... 1.40 

Flange Type Installation 

Module..................................... 1.44-1.49 

Horizontal Rapid Clamping Cylinder.....1.50 

Threaded Clamping Module....... 1.44-1.45 

Raised/Mounted Clamping 

Module..................................... 1.46-1.47 

The Zero Point System............... 1.36-1.39 

Phone 800-537-4367 or +1 216-486-5540 • Fax: +1 216-481-6193 • E-mail: info@jergensinc.com • www.jergensinc.com 1.1

1 BALL LOCK ® MOUNTING SYSTEM 


We Put It All Together… In Seconds. 

Maximize productivity levels and 

dramatically increase throughput with 

Ball Lock ® . 

Looking to realize the full benefits of lean manufacturing? Then 

you need the one system that puts it all together, so you can put 

it all together…and that’s Ball Lock ® . 

Ball Lock ® is the industry’s most popular quick-change, fixturingflexible 

mounting system that can be configured to create leanoptimized 

solutions for your most demanding needs. 

The Ball Lock ® Mounting System is used as a 

Quick Change Solution on the following: 

• CNC Machines 

• Palletized Fixtures 

• Stamping 

• Fabricating 

• Injection Molding 

• Packaging Machines 

• Assembly Machines 

• EDM 

• Robotics 

• Welding Fixtures 

1.2 

Jergens, Inc. • Jergens Way • 15700 S. Waterloo Road • Cleveland, Ohio 44110-3898 USA


BALL LOCK ® 

MOUNTING SYSTEM 

1 

Lean Manufacturing and Set Up Reduction Applications 

Accurately Locate and Lock Fixture Plates to Subplates in Seconds… 

With No Indicating Required. 

Machining Cast Part 

Previous Set Up Method: 

Located part with dowel pins, bolted part to tombstone 

fixture. Indicated part to zero datum point. 

Set Up Using Ball Lock ® System: 

Mount parts to fixture plate while machining other 

parts. Mount fixture plate to tombstone using Ball 

Lock ® shanks. No indicating required because 

system provides + 0.0005 (±0.013mm)repeatability. 

Previous Set-Up Time: 

15 minutes 

Set Up Time With Ball Lock ® System: 

60 seconds 

CNC Machine Base: 

Drilling and reaming forged part. 


Fixture plate located with dowel pins bolted to 

machine base. Fixture plate and parts indicated. 


Parts are pre-mounted on fixture plate, which is 

then mounted to machine base using Ball Lock ® 

shanks. No need to indicate. 

Previous Set Up Time: 

7 minutes 

Set Up Time with Ball Lock ® System: 

60 seconds 

CNC Vertical Machining Center 

Machining aircraft valve parts 

Previous Set Up Method:New Project. New 

Machine.No Prior History. 

Set Up Using Ball Lock ® System:Using Ball 

Lock ® Jig Saw Plate on Multi-Purpose Subplate 

enables operator to mount two more vises on 

the fixture. No indicating needed. 


New Set Up. 

Set Up Time With Ball Lock ® System: 

80 seconds setting up six vises. 

Two-Sided Tombstone 

Drilling and tapping cylindrical bodies. 


Fixture located and bolted to tombstone. Had to 

be indicated. 


Fixture plate mounted and located with Ball Lock ® 

shanks. No need to indicate. 


12 minutes 

Set Up Time with Ball Lock ® System: 

45 seconds 




Locates 

The Ball Lock ® System accurately positions 

your fixtureplate with a repeatability of 

±0.0005" (±0.013mm) or better, minimizing 

the need to indicate your fixture. 

Locks 

The Ball Lock ® System securely holds fixture 

plates to subplates with up to 20,000 lbs. 

(9000 kg) of hold-down force per shank. 

The Ball Lock ® Mounting System is designed 

to speed the accurate locating and locking 

of fixture plates to subplates. The system 

consists of three parts: a Locating Shank, 

a Liner Bushing, and a Receiver Bushing. 

Using the Ball Lock ® Mounting System is 

a simple process: Install a subplate with 

receiver bushings on your machine table; 

add your fixture plate with two locating liner 

bushings; then insert two locating shanks 

through the liners and into the receiver 

bushings to provide accurate location. 

2 1 / 2 turns of the set screw in each of the 

locating shanks provides positive holding 

force. Additional Ball Lock ® Shanks are 

inserted through clearance holes in the 

fixture plate and set screws tightened for 

additional holding force distributed across 

the fixture plate. 

It is recommended that the use of 

the Ball Lock ® Mounting System for 

locating and clamping of fixture plates 

be incorporated in a systematic 

process. All fixture plates should 

have two locating points positioned 

as far apart as possible. There is no 

advantage to having more than two 

The Ball Lock ® Mounting System 

provides a method of quickly and 

accurately locating fixtures onto 

machine tables. The Ball Lock ® 

Mounting System has done for 

machining centers what the Japanese 

SMED concept did for presses. 

Instead of single minute exchange of 

dies, Ball Lock ® provides single minute 

exchange of fixtures. Fixtures can 

often be exchanged in less than a 

minute and with position repeatability 

of ±0.0005” (±0.013mm). Fixtures 

can be exchanged between different 

machines when both are using the 

Jergens Ball Lock ® Mounting System. 

Commonly Asked Questions 

Q. What is the Ball Lock ® 

Mounting System? 

A. It is a means of locating and locking 

two flat surfaces together, normally a 

fixture plate and a sub-plate. 

Q. How does it locate? 

A. Similar to locating pins, two Ball 

Lock ® shanks (pins) pass through two 

precision liner bushings on the fixture 

plate and into two precision receiver 

bushings on the subplate. 

Q. How does it lock? 

A. Inside the shank are three balls that 

expand into a tapered groove in the 

receiver bushing. This action draws 

the plates together. The locking balls 

are activated by turning a setscrew in 

the head of the shank, which pushes 

a 4th ball to distribute the clamping 

forces between the 3 locking balls. 

Q. How many shanks are required 

to locate and lock each fixture? 

A. Only two shanks, passing through 

bushings in the fixture plates, are 

required for location. However, 

additional shanks passing through 

clearance holes in the fixture plate 

will provide additional holding force 

distributed across the plate. 

1.4 





1 

Ball Lock ® 

Shank 

Liner Bushing 

Ball Lock ® 

Shank 

Liner Bushing 

Fixture Plate 

Fixture Plate 

Slip Fit Hole 

Socket Head Cap 

Screws (3) 

Press Fit Hole 

Machine 

Table or 

Subplate 

Face Mount 

Bushing 

Drilled Hole 

Subplate 

Counter-Bored 

Hole 

Back Mount Bushing 

Mounting Method With 

Face Mount Bushing 

Mounting Method With 


locating points. If more than two flanged 

shanks are required to provide additional 

holddown force, omit liner bushings in 

the additional holes in the fixture plate and 

allow 0.030" (0.76mm) over the nominal 

size. The additional clearance will insure 

that these holes have no influence on the 

locating holes. 

How accurate should positioning be? 

The center distance of the receiver bushings 

in the machine table, tombstone, or subplate 

should be as accurate as possible ±0.0002" 

(±0.005mm) recommended. Accurate 

location will assure interchangeability of 

numerous fixture plates. For accurate 

repeatability within ±0.0005" (±0.013mm) 

of true position, both liner bushings in the 

fixture plate should be primary liners and 

the center distance tolerance should be 

±0.0002" (±0.005mm). For a slightly looser 

fit, repeatability within 0.0015" (0.04mm) 

of true position, use one primary and one 

secondary liner with a center distance 

tolerance of ±0.001" (±0.003mm). 

Q. Is there a preferable location for 

the liner bushing? 

A. System repeatability is improved 

if the liners are located at opposite 

corners of a rectangular fixture plate. 

For consistency, we recommend 

locating the liner bushings at top left 

and bottom right. 

Q. What are the advantages of using 

the Ball Lock ® System over the 

conventional method of dowel 

pins and cap screws? 

A. Both locating and locking are 

accomplished in the same motion. Ball 

Lock ® shanks require only 2.5 turns 

to lock a 1/2–13 (M12) screw with ¾" 

(18mm) of thread engagement require 

10 turns to lock. On CNC machines, 

the repeatability of fixture locations 

makes indicating of the fixture 

unnecessary. 

Q. How do I recess the fixtureplate 

for a clear surface ? 

A. Counterbore the fixture plate to a 

diameter large enough to allow easy 

removal of the shank. 

Note: The thickness of the plate section 

under the head of the shank is critical and 

must conform to mounting instructions . 

Q. What if my plate is thinner than 

the recommended thickness? 

A. By adjusting the depth of the 

counterbore for the receiver bushing 

in the subplate, you can still use the 

Ball Lock ® System. If there are any 

questions on this type of application, 

please call 1-800-JERGENS. 

Q. Can I use the shanks in a heated 

environment? 

A. The shank is made of alloy steel, 

heat treated to 40-45Rc and should 

with stand temperatures up to 400°F. 

(200°C). 

Note: Thermal expansion of fixture plates 

may affect the center distance tolerance 

and repeatability. 



INCH DIMENSIONS 


INCH PRE-MACHINED FIXTURE/SUBPLATES 

Multi-Purpose Subplates 

40x20 Multi-Purpose Subplate 

Part Number Wt. (lbs) 

49112 285 

The Jergens Multi-Purpose Subplate accommodates 

a wide variety of fixture plates and vises. This 

versatility facilitates using the same VMC for 

diverse products in repetitive runs, long and short 

batch sizes. 

• FreMax 15 Steel or Equivalent 

• Thickness: 1 1/4” ±0.005" 

• Parallel within 0.001" 

28706 

28801 

49406 

28719 

28713 or 28715 

28727 

49112 

17.0000 

12.0000 

17.0000 

12.0000 

(18) 20MM FACE MOUNT 

BUSHINGS 

INSTALLED 

5/8" BORED HOLE 

FOR SINE 

FIXTURE KEYS 

(2) PLACES 

6.0000 

12.0000 

20 

17.0000 


BUSHINGS 

INSTALLED 

8.0000 

8.0000 

8.0000 

8.0000 

40 

Fixture Plate Options for Multi-Purpose Subplates – Aluminum or Steel 

Number of Fixture Receiver Required Number 

Plates/Vises That Mount Bushing Receiver Ball Lock ® of Shanks 

Fixture Plate*/Vise Thickness of on Multi-Purpose Center Bushing Shank Required Per 

Part Number Fixture Plate Subplate Distance Size Part Number Fixture Plate/Vise 

28713 (14 x 14) 

Fixture Plate 

28715 (16 x 16) 

Fixture Plate 

28801 (16 x 16) 

Modular Grid Plate 

28706 Jigsaw 

Interlocking Plate 

28727 (20 x 20) 

Fixture Plate 

28719 (20 x 16) 

Fixture Plate 

49406 

6" Jigsaw Base Vise 

3/4” 2 12 x 12 20 mm 49601 4 

3/4” 2 12 x 12 20 mm 49601 4 

1 1/8”** 2 12 x 12 20 mm 49602 4 

3/4” 4 8 x 12 20 mm 49601 3 

1” 2 17 x 17 25 mm 49612 4 

3/4" 1 16 x 12 20 mm 49601 4 

3/4" 4 8 x 12 20 mm 49601 3 

* See next page for dimensional data on fixture plates. Part numbers shown for aluminum plates, also available in steel. 

** Counterbored to 1" at mounting holes. 

1.6 






1 

Fixture Plates for Multi-Purpose Subplate 

14x14x3/4" Fixture Plate 

Aluminum Plate 


28713 14 




28715 18 

Steel Plate 


28813 42 

Steel Plate 


28815 55 

• Cast Aluminum or FreMax 15 Steel or equivalent 

• Thickness: 3/4" ±0.005" 

• Parallel within 0.001" Steel 

• Mounts to subplates with Ball Lock ® Shank 49601 (20 X 3/4") 

16x16 Modular Grid Fixture Plate 

Steel Plate 


28801 80 

(2) 20MM 

PRIMARY LINERS 

• FreMaxINSTALLED 

(2) PLACES 

15 Steel or equivalent 

• Thickness: 1 1/8” ±0.005" 


• Mounts to subplates with Ball Lock ® 

Shank 49602 (20 x 1") 

(2) 20MM 


INSTALLED 

CLEARANCE HOLES 

FOR HOLDDOWN 

CLEARANCE 

12.0000 

HOLES 

FOR HOLDDOWN 

(2) PLACES 16.0000 

-0.000 

.625 +0.0005 x .25 Deep 

COUNTERBORE 

1/2-13 

TAPPED HOLE 

-0.000 

.625 +0.0005 x .25 Deep 

COUNTERBORE 


12.0000 

12.0000 

Clearance holes for 

holddown (2) 

places 

5/8” Bored hole for 

sine fixture keys 

(2) places 

12.0000 

16.0000 

1.50 

TYP 

12.0000 

16.0000 

1/2-13 

TAPPED HOLE 

6.000 

(2) 20mm Primary 

Liners Installed 

12.0000 

16.0000 

1.50 

TYP 

Jigsaw Interlocking Fixture Plate 

Aluminum Steel Plate Jergens Vise 

Plate Part No Wt. Part No Wt. A B C D P/N 

28705 6 - - 7.97 5.97 15.00 6.0000 49401 

28706 11 28806 34 9.97 7.97 16.00 8.0000 49402 


• Thickness: 3/4” ±0.005" 


• For use with narrow base 4" or 6" vise models 

• Design allows close vise spacing for more parts per run 

• Easily mounts to Subplates using the 

Ball Lock ® Shank 49601 (20 x 3/4") 

• Useful for high density fixturing of small parts 

20x20x1" Fixture Plate 



28727 38 


• Thickness: 1” ±0.005" 


• Mounts to subplates with Ball Lock ® Shank 49612 (25 X 1") 

17.0000 

Steel Plate 


28827 114 

Clearance 

Clearance 

hole 

hole for 

for holddown 

17.0000 

Clearance holes for 

holddown (2) places 

5/8” Bored hole 

for sine fixture key 

(2) places 

A 

B 



12.0000 

6.0000 

D 

8.500 



C 





Ball Lock ® Standard Subplates 


12.0000 

6.000 

• • 

• 

• • 

• 

12.0000 

5/8 Bored holes for 


(2) places 

(2) 20mm face mount 

bushings installed 

• • 

• 

• • 

• 

16x16 Subplate 

Part Number Wt (lbs) 

49101 81 

Equipped with four 20mm receiver bushings for use 

with 14x14 or 16x16 fixture plates. Ideal for horizontal 

machining centers or multiple pallet machining centers. 

• Fremax 15 steel plate or equivalent 

• Thickness: 1-1/8" ±0.005" 


1.600 

9.0000 12.5 

25x16 Dual Station Subplate 

• • 

• 

• • 

• 

• • 

• 

• • 

• 

• • 

• 

• • 

• 


49111 128 

12.0000 

11.000 

28713 or 28715 

16 

6.000 



(2) places 



28711 

2.0 

• • 

• 

• • 

• 

• • 

• 

• • 

• 

• • 

• 

• • 

• 

49111 

6.000 

12.0000 

Aluminum Steel Plate Number Plate 

Plate Part Part of Fixture Width and 

Number Number Plates Length 

28713 28813 1 14"x14" 

28715 28815 1 16"x16" 

28711 28811 2 12"x14" 

25 

Equipped with twelve installed 20mm receiver bushings to 

easily locate and mount Jergens Standard Fixture Plates: 

• Fremax 15 steel plate or equivalent 

• Thickness: 1-1/8" ±0.005" 


3/4 

˚˚˚ 

˚ 



(2) places 

(4)1/2 dia. for 

mounting to table 



12.0000 

15 

˚˚˚ 

2.50 

8.0000 10 

2.50 

˚ 

15x10 Bridgeport - Style Subplate 


49121 32 

Equipped with four installed 16mm receiver bushings 

and 1/2" mounting holes. Used with the Bridgeport style 

fixture plates 28731 or 28831. 

• Thickness: 3/4" ±0.005" 


Ball Lock ® Quick Change Kits include all components needed in a single package. See page 1.13 for details. 

1.8 






1 

Ball Lock ® Fixture Plates 

• Cast Aluminum or FreeMax 15 Steel or equivalent 

• Thickness tolerance ±0.005" 


• 6061–T-651 Aluminum plates, within .001 available upon request 

Aluminum Ball Lock ® Fixture Plates with 2 Primary Liners Installed 

Plate Part 

Plate Part 

Number Weight Number Weight 

Aluminum (lbs) Steel (lbs) 

Plate 

Dimensions 

(in.) 

Plate 

Thickness 

(in.) 

±.005 

Shank Size 

Dia. (mm) 

Ball Lock ® 

Shank 

Part 

Number 

28706 9 28806 34 9.97 x 16 3/4 20 49601 

28711 12 28811 36 12 x14 3/4 20 49601 

28713 14 28813 42 14 x14 3/4 20 49601 

28715 18 28815 55 16 x 16 3/4 20 49601 

28722 16 28822 48 12 x 14 1 25 49612 

28724 19 28824 56 14 x 14 1 25 49612 

28726 24 28826 73 16 x 16 1 25 49612 

28719 23 28819 68 20 x 16 3/4 20 49601 

28727 38 28827 114 20 x 20 1 25 49612 

28731 11 28831 32 15 x 10 3/4 16 49608 

– – 28801 80 16 x 16 1 1/8 20 49602 

• Machined to close tolerances 

• Repeatability ±0.0005" or better 

• Reduces fixture set-up and 

assembly time 

• Provided with 5/8" bored holes for 


• For horizontal or vertical machining 

centers, Tool Room Mills, or 

multiple pallet machining centers 


Custom Sizes Available 

Jergens will make Ball Lock ® fixture plate or subplates to your 

specifications. Call 1-800-JERGENS for further information. 

15x10x3/4" Fixture Plate Bridgeport Style 




28731 11 

Steel Plate 


28831 32 



28711 12 

Steel Plate 


28811 36 

9.0000 

4.000 

Clearance Hole for 

Holddown (2) Places 

5/8 Bored Holes for 

Sine Fixture Keys 

(2) Places 



8.0000 

12.0000 

Clearance Hole for 




(2) places 

12.0000 

6.000 







Ball Lock ® T-Columns 

Fixture 

Plate 


• Class 40 Cast Iron 

• Also available in Aluminum 

• Ball Lock ® Receiver Bushings and Liner Bushings installed 

• Perpendicularity is 0.001" per foot 

Custom Sizes Available with or without Ball Lock ® 

We are able to quote you on your special requirement 

with or without the Ball Lock ® Mounting System. 

Call 1-800-JERGENS for design specification information. 

Subplate 

Tooling 

Column 

Cast Iron T-Columns With 

Ball Lock ® Receiver Bushings Installed 

See page 1.12 for Fixture Plates and Subplates 

Pallet Part O P Wt. 

Size (mm) Number C D E F G H I J K L M N (mm) (mm) (lbs) 

400 69101 16.375 1 16 16 14 14 14 14 4 19.875 4.875 3.5 20 20 425 

500 69111 22.375 1 20 20 19 17 17 17 4.7 25.875 5.375 3.5 25 25 700 

630 69121 26.375 1.5 25 25 23 22 21 21 4 29.875 5.375 3.5 35 25 1125 

*Note: Window sections are also available on T-Columns. Specify window size and location (Q and R Dimensions). 

Corresponding Fixture Plates, Subplates and Ball Lock ® Shanks 

Pallet T-Column Aluminum Steel Fixture Fixture Plate Subplate 

Size Part Fixture Plate Fixture Plate Plate Ball Lock ® Shank Shank Subplate Ball Lock ® Shank Shank 

(mm) Number Part Number Part Number Size Part Number Size Part Number Part Number Size 

400 69101 28717 28817 16 x 16 49601 20mm x 3/4 49102 49602 20mm x 1 

500 69111 28745 28845 20 x 22 49612 25mm x 1 49103 49612 25mm x 1 

630 69121 28746 28846 25 x 26 49612 25mm x 1 49104 49633 35mm x 1-1/2 

Use Hoist Ring 23411, see page 11.8 for lifting and handling – Order separately. 

Engineering Changes 

Product improvement is a continuing process at Jergens. Specifications and engineering data are subject to change 

after publishing. Contact Jergens Technical Sales Department to verify any dimensions or specifications. 

1.10 






1 

Ball Lock ® 4-Sided Tooling Columns 



• Ball Lock ® Receiver Bushings and Liners installed 

• Provides accurate fixturing base for CNC machining centers 

• Perpendicularity is 0.001" per foot 




Call 1-800-JERGENS for design specification information. 

Tooling 

Column 

Subplate 

Fixture 

Plate 


Cast Iron 4-Sided Tooling Columns With 


See page 1.12 for Fixture Plates and Subplates 


Size (mm) Number A B C D E F G H I J K L M N (mm) (mm) (lbs) 

400 69001 10 10 20 1 16 16 18 6.75 14 14 1.75 23.875 4.875 3.875 20 20 510 

500 69011 12 12 25 1 20 20 22 8 17 17 1.625 28.875 5.375 3.875 25 25 736 

630 69021 16 16 26 1.5 25 25 23 11.50 21 21 2 29.875 5.375 3.875 35 25 1122 





400 69001 28741 28841 10 x 20 49601 20mm x 3/4 49102 49602 20mm x 1 

500 69011 28742 28842 12 x 25 49612 25mm x 1 49103 49612 25mm x 1 

630 69021 28743 28843 16 x 26 49612 25mm x 1 49104 49633 35mm x 1-1/2 










Subplates For Tooling Columns and Fixture Plates 

5/8 Bored holes 

for sine fixture 

keys (2) places 

Receiver 

Bushings 

Installed 

A 


for sine fixture keys 

(2) places 

Clearance Hole 

for Holddown 

(2) Places 

(2) Primary Liners 

Installed 

B 

Standard Steel Subplates for Tooling Columns 

Subplate Mounting holes can be provided per customer specification. 

Supplied with Ball Lock ® Receiver Bushings installed. 

Ball Lock ® Pattern Receiver Thickness of 

Part Pallet Size For Tooling A B Size Subplate Wt 

Number (mm) Columns (in.) (in.) (mm) (in.) ±.005 (lbs) 

49102 400 69001, 69101 14 14 20 1 1/8 79 

49103 500 69011, 69111 17 17 25 1 1/4 137 

49103-C* 500 69101, 69001 14/17 14/17 20/25 1 1/4 137 

69111, 69011 Dual Dual Dual 1 1/4 

49104 630 69021, 69121 21 21 35 1 3/8 240 

*49103-C is a dual pattern subplate. Please contact Jergens Technical Service at 1-800-Jergens for 

design specific information. 

Fixture Plates for Standard Tooling Columns and T-Columns 

Supplied with 2 primary Ball Lock ® Liner Bushings installed. 

Fixture Fixture Plate Ball Lock ® Pattern Liner 

Pallet Part Number For Tooling Plate Size Thickness H G Size 

Size (mm) Aluminum (lbs) Steel (lbs) Columns Type (in.) ±0.005" (In.) (In.) (mm) 

400 28741 14 28841 43 69001 4-S 10x20 3/4 6.75 18 20 

500 28742 28 28842 85 69011 4-S 12x25 1 8 22 25 

630 28743 39 28843 118 69021 4-S 16x26 1 11.50 23 25 

400 28717 18 28817 55 69101 T 16x16 3/4 14 14 20 

500 28745 41 28845 125 69111 T 20x22 1 17 19 25 

630 28746 61 28846 184 69121 T 25x26 1 22 23 25 

Clearance Hole 

for Holddown 

(2) Places 




(2) Primary Liners 

Installed 

J 

E 

I 

F 

Fixture Plates for Tooling Column Subplates 


Ball Lock ® 

Pallet Part Number Plate Dim. Fixture Plate Pattern Liner 

Size For E F Thickness I J Size 

(mm) Aluminum (lbs) Steel (lbs) Subplate (In.) (in.) ±0.005" (In.) (In.) (mm) 

400 28717 18 28817 55 49102 16 16 3/4 14 14 20 

500 28727 38 28827 114 49103 20 20 1 17 17 25 

630 28732 58 28832 177 49104 25 25 1 21 21 35 

Difference between Aluminum and Steel 


(inches) 

(inches) 

0.00015 

0.000125 

0.0001 

0.000075 

0.00005 

0.000025 

Aluminum and Steel Expansion 

(per (per inch) inch) 

0 0 

0 0 5 5 10 10 15 15 20 20 25 25 30 30 

Change in Degrees in F F 

NOTE: Aluminum and steel expand at different rates. Please take this information into 

consideration when creating your own Ball Lock ® fixture and subplates. 

1.12 






1 

Quick Change Kits 

The Jergens Ball Lock ® Quick Change Kits speed fixture changeover in 

all types of manufacturing operations. Each kit includes two aluminum 

fixture plates with two primary liner bushings installed; one steel 

subplate with receiver bushings installed, and four 20mm Ball Lock ® 

shanks with working loads of 3000 lbs. each. While one fixture plate is 

on the machine, the operator can load parts on the other. This minimizes 

downtime for true set-up reduction. To enable the subplate to be 

mounted on a slotted table without the need to indicate the subplate, 

sine fixture keys can be used. The sine fixture key bored holes are 

oriented parallel to the receiver bushings on the subplate and to the 

liner bushings on the fixture plate. These also allow the fixture plate 

to be mounted on a toolroom mill 

without the need to indicate it. This 

is extremely useful when machining 

location points on your fixture. 


Everything You Need to Change Fixtures in Less Than One Minute 

Aluminum Fixture Plate 

Steel Subplate 

5/8" Bored 

Hole for Sine 

Fixture Keys 

5/8" Bored 

Hole for Sine 

Fixture Keys 

Ball Lock ® Shank 

Primary Liner 

Bushings (2 places) 

Receiver 

Bushings 

(4 places) 


Part No. Kit Includes 

49001 2 - 28713 (14"x14"x3/4") aluminum 

fixture plates with 20mm liner 


1 - 49101 (16"x16"x1-1/8") steel subplate 

with receiver bushings installed 

4 - 49601 (20mm) Ball Lock ® Shanks 

49002 2 - 28715 (16"x16"x3/4") aluminum 



1 - 49101 (16"x16"x1-1/8") steel subplate 



49004 Bridgeport-Style 

2 - 28731 (10"x15"x3/4") aluminum fixture 

plates with 16mm liner bushings 

installed 

1 - 49121 (10"x15"x3/4") steel subplate 




Mounting 

System 

*HAAS is a trademark of HAAS Automation, Inc. 


Pre-Engineered Ball Lock ® Fixture Kits for HAAS* 


PRE-MACHINED FIXTURE/SUBPLATES 

Ball Lock 

Ball Lock ® Mounting System 

Jergens Introduces Another Piece to the Quick Change Puzzle 

Ball Lock ® 

Fixture Kits 

For HAAS * 

HAAS models: 

• MINI MILL 

• VF-E 

• VF-O 

• VF-1 

• VF-OE 

• VF-2 

• VF-3 

• VF-4 

• VF-5 

Changes Fixtures in 60 Seconds 

Kits for other machine ...or Less 

manufacturers available. 

Pre-Engineered HAAS Kits 

available. PDF Catalog 

Available at 


These kits include: 

• Steel Subplate with receiver bushings 

• Aluminum Fixture Plate(s) with 2 primary liner bushings 

• Pre installed receiver and Liner Bushings 

• Ball Lock ® Shanks 

• T-Slot nuts for mounting subplate to machine table 

• 2 Sine Fixture Keys for accurate subplate locating 

• Socket head cap screws 

Benefits: 

• Save time specifying and ordering 

• Saves installation time and cost 

• Eliminates potential installation errors 

Ask about these other machine manufacturers where 

Ball Lock ® kits can be utilized. 

Call customer support at 1-800-537-4367 

Acer 

Bridgeport 

Brother 

Chevalier 

Chiron 

DMG 

Enshu 

Excel 

Fanuc Robodrill 

HAAS 

Hardinge 

Hitachi 

Hitachi Seiki 

Hurco 

Hyundai-Kia 

Johnsford 

Kira Mill 

Kitamura 

Leadwell 

MAG 

Makino 

Matsuura 

Mazak 

Milltronics 

Miyano 

Mori-Seiki 

OKK 

Okuma 

Republic Lagun 

Toyoda 

Tree 

YCI 

*HAAS is a trademark of HAAS Automation, Inc. 

1.14 





1 

Set-Up Reduction Worksheet 

Benefits of Set-Up Reduction (Capacity) 

Current Method 

Minutes per set-up = minutes 

Number of set-ups 

per 8 hour shift = set-ups 

Total minutes of set-up per shift 

(set-up minutes x number of set-ups) = minutes 

Using the Ball Lock ® System 

Minutes per set-up = minutes 

Example (actual case study): 

60 minutes 

1.5 set-ups 

90 minutes 

8 minutes 


Number of set-ups 

per 8 hour shift = set-ups 

Total minutes of set-up per shift 

(set-up minutes x number of set-ups) = minutes 

Increased capacity per machine per shift 

(current method - Ball Lock ® method) = minutes 

Savings per machine per shift = minutes 

Increased capacity 

(number of minutes / 60) = hours 

1.5 set-ups 

12 minutes 

78 minutes 

78 minutes 

1.3 hours 

Benefits of Set-Up Reduction (Profit) 

Machine cost per hour = $ $80.00 

Increased production hours per shift 

(increased capacity from above) = hours 1.3 hours 

Savings (profit) per machine per shift 

(machine cost per hour x increased = $ per machine $104.00 per machine 

production hours) per shift per shift 





Ball Lock ® For 4th Axis Rotary Indexers 

Problem: 

Rotary indexers increase the versatility of vertical machining 

centers, yet they offer one major challenge: set-up is so timeconsuming 

that it may limit a machine’s flexibility. In many cases, 

machinists dedicate their 4th Axis tool to a single machine to 

avoid the agony of an extended set-up and changeover. 

Benefits: 

• Maximize indexer utilization 

• Eliminate lengthy set-ups 

• Accurate fixture plate changover in seconds 


Jergen’s Solution: 

Ball Lock ® Mounting System for Indexers provides a double 

solution. 

First, Ball Lock ® mounting plates free up your machine for 

additional work by allowing a fast and accurate installation 

and removal of the complete indexer. Avoid hours of set up. 

The Ball Lock ® System does it in minutes, with repeatability at 

±.0005" (±.013mm). Low profile, positive clamping, proven in 

over many years of field use. 

Second, the Ball Lock ® System provides your fixture plate 

changeover. By mounting the round subplate to the indexer 

faceplate, you’ll “plug-in” new fixtures in record time 

(less than 60 seconds). 

Indexer Face Plate 

Ball Lock ® 

Subplate 

Ball Lock ® 

Shanks 

Ball Lock ® 

Fixture Plate 

For Holding 

Production 

Workpiece 

Workpiece 

Ball Lock ® Fixture Plate 

For Mounting Indexer 

to Subplate and 

Machine Table 

Subplates and fixture plates come with bushings pre-installed. 

1.16 






Round Ball Lock ® Fixture Plates and Subplates 

1 

Standard Round 

Cast Aluminum, FreeMax or Steel equivalent 

Custom Round Plates 

Fixture Plate 

Part Thickness Ball Lock ® Ball Lock ® Weight 

No. A B ±0.005" Liner Shank (lbs) 

28707 8" 6" 3/4 16mm 49608 3.5 

28708 10" 8" 1 20mm 49602 7.0 

28709 12" 10" 1 20mm 49602 11.0 

Subplate 

Part Thickness Ball Lock ® Center Weight 

No. A B ±0.005" Receiver Hole (lbs) 

49107 8" 6" 3/4 16mm 1.00" 11.0 

49108 10" 8" 1 20mm 2.00" 21.0 

49109 12" 10" 1 20mm 2.00" 33.0 

Metric sizes also available; please call for information. 


Indexer: 

Make: 

Model: 

Diameter: 

Light Duty or Heavy Duty: 

Through Hole Bore: 

CNC Machine: 

Make: 

Model: 

Weight Capacity: 

Indexer Faceplate: 

T-Slot Size: 

Configuration/Orientation: 

or 

Drilled Tapped Hole Size: 



Product improvement is a continuing process at Jergens. Specifications and engineering data are subject to change without notice. 

If current information is critical to your design, it is suggested that you contact Jergens Technical Sales Department to verify any 

dimensions or specifications. 





Locating and Clamping Shanks 

• Material: Shank/Bushing, 4340 

Liner, 52100 

• Finish: Black Oxide 

• Heat Treat: Shanks, RC 40-45 

Bushings, RC 50-54 

Liners, RC 62-64 

• Operating Temperature Range 

-20° to 400°F, -30° to 200°C 

D 

C 

B 

Stainless Steel available 

A 

INCH BALL LOCK ® COMPONENTS 

Ball Lock ® Repair Kits 

Each Kit Includes: 

• Replacement Screw 

• Locking Balls 

• Drive Ball 

• O-Ring 

Locating and Clamping Shank Dimensions 

Shank 

Diameter 

(mm) 

A 

Fixture 

Plate 

Thickness 

± 0.005 

Shank 

Part 

Number 

Head of Shank 

Height 

B 

Diameter 

C 

Length 

Under Head 

D 

Hex Wrench 

Size for 

Set Screw 

Any Ball Lock ® application requires at least two sets of 

shanks, receiver bushings and liners. The liners are 

placed into the fixture plate to insure extremely accurate 

positioning. If more than two shanks are required (to 

provide additional hold down force), omit the liner 

bushing so that these additional holes will not interfere 

with your primary locating holes. 

See page 1.20 for Fast Acting Shanks. 

Screw 

Torque 

(Ft/lb) 

Maximum 

Hold-Down 

Force 

(lbs) 

Recommended 

Screw 

Torque 

(Ft/lb) 

Hold-Down 

Force 

(lbs) 

Shank 

Repair Kit 

Part 

Number 

13 0.50 49605 0.25 0.87 1.08 3/32 1.2 750 1 625 49905 

0.75 49606 1.33 49906 

16 0.50 49607 0.32 1.50 1.15 1/8 3 1200 2 800 49907 

0.75 49608 1.40 49908 

20 0.75 49601 0.38 1.75 1.53 1/8 4 3000 3 2250 49901 

1.00 49602 1.78 49902 

25 0.75 49611 0.38 2.00 1.70 5/32 9 7000 7 5444 49911 

1.00 49612 1.95 49912 

30 0.75 49621 0.50 2.25 1.88 3/16 15 10000 12 8000 49921 

1.00 49622 2.13 49922 

35 0.75 49631 0.50 2.25 1.97 1/4 25 15500 19 11780 49931 

1.00 49632 2.22 49932 

1.50 49633 2.72 49933 

2.00 49634 3.22 49934 

50 0.75 49641 0.75 3.00 2.45 3/8 50 20000 38 15200 49941 

1.00 49642 2.70 49942 

1.50 49643 3.20 49943 

2.00 49644 3.70 49944 

1.18 






1 

Receiver Bushings 

Two styles of receiver bushings are available. 

Generally, the face mount receiver bushing is 

utilized in blind hole applications (Slip Fit). 

The back mount receiver bushing is used in 

through hole applications (Light Press Fit). 

Note: Installed bushings should be approximately 

.012" below subplate surface. 

See reference below for installation of back mount 

style bushings. 

Back Mount 

Face Mount 

Installation Dimensions 

Face Mount 

Shank 

Dia. 

(mm) 

Face 

Mount 

Part 

Number 

Actual 

O.D. 

+0.0000 

-0.0004 

Clearance 

Drill 

Diameter 

E 

Bore 

+0.0005 

-0.0000 

F 


Installation Instructions 

Depth 

+0.002 

-0.000 

G 

Tap 

Size & 

Depth 1 

H 

13 49506 1.3750 11/16 1.3750 0.469 8-32x5/16 0.984 

16 49507 1.4370 13/16 1.4370 0.469 8-32x5/16 1.125 

20 49501 1.6873 13/16 1.6873 0.637 10-32x3/8 1.362 

25 49502 2.0623 1 2.0623 0.799 1/4-28x1/2 1.644 

30 49503 2.2654 1 3/16 2.2654 0.871 1/4-28x3/4 1.876 

35 49504 2.6873 1 9/16 2.6873 0.904 5/16-24x7/8 2.178 

50 49505 3.4998 2 5/32 3.4998 1.239 3/8-24x1 2.916 

Cap Screws Supplied with Face Mount Bushings. 

1 

Bolt Circle Min. 

Diameter Subplate 

3 PL Equally Thickness 

Spaced D 

3/4 

3/4 

1 

1-1/4 

1-3/8 

1-1/2 

2 

Back Mount 

Shank 

Dia. 

(mm) 



Back 

Mount 

Part 

Number 

Actual 

O.D. 

+0.0000 

-0.0004 

A 

Depth 

+0.000 

-0.002 

B 

C-Bore 

±0.006 

C 

13 49516 0.7870 .277 1.000 

16 49517 0.8760 .285 1.155 

20 49511 1.0950 .345 1.280 

25 49512 1.3763 .416 1.593 

30 49513 1.6264 .432 1.906 

35 49514 1.8764 .493 2.155 

50 49515 2.6269 .621 2.988 

Min. 

Subplate 

Thickness 

D 

3/4 

3/4 

7/8 

1 

1-1/4 

1-5/16 

1-3/4 


Liner Bushings for Fixture Plates 

Liner Dimensions 

Locating repeatability will determine if one primary and one 

secondary or two primary liners are needed. With two primary 

liners, repeatability of ±.0005" can be maintained if the two 

holes for receiver bushings are held to a centerline distance 

of ±.0002" tolerance. 

Note on Installation of Press Fit Liners & 

Back Mount Style Receiver Bushings: 

To alleviate the possibility of binding the 

shank in the bore, the maximum interference 

fit between bore and bushing O.D. should not 

exceed .0005". 

Fixture Plate 

Thickness 

±0.005 

Shank 

Diameter 

(mm) 

Primary 

Liner 

Part 

Number 

Secondary 

Liner 

Part 

Number 

Liner O.D. 

+0.0000 

-0.0004 

.50 13 49705 49805 0.7518 

.75 13 49706 49806 0.7518 

.50 16 49707 49807 1.0018 

.75 16 49708 49808 1.0018 

.75 20 49701 49801 1.3772 

1.00 20 49702 49802 1.3772 

.75 25 49711 49811 1.3772 

1.00 25 49712 49812 1.3772 

.75 30 49721 49821 1.7523 

Fixture Plate 

Thickness 

±0.005 

Shank 

Diameter 

(mm) 

Primary 

Liner 

Part 

Number 

Secondary 

Liner 

Part 

Number 

Liner O.D. 

+0.0000 

-0.0004 

1.00 30 49722 49822 1.7523 

.75 35 49731 49831 1.7523 

1.00 35 49732 49832 1.7523 

1.50 35 49733 49833 1.7523 

2.00 35 49734 49834 1.7523 

.75 50 49741 49841 2.5025 

1.00 50 49742 49842 2.5025 

1.50 50 49743 49843 2.5025 

2.00 50 49744 49844 2.5025 




Accessories 


Tapered Caps 

and Plugs 

Keep debris out 

of your subplate’s 

receiver bushings 

when not in use. 

Polyethylene caps 

snap in and out easily. 

Packaged 

10 per 

pack. 

Receiver 

Bushing Part 

Diameter Number 

13 49201 

16 49202 

20 49203 

25 49204 

30 49205 

35 49206 

50 49207 

Lifting Handles 

For easy handling of fixture plates up 

to 500 lbs. 

Part Number Length Ht. W Mounting Distance 

33701 4.21 1.42 0.83 3.68 



Locate subplates or fixture 

plates to slotted machine tables 

without having to slot the plate. 

Available in inch sizes from 1/2" 

to 7/8" slots, and in metric sizes 

from 14mm to 22mm slots. 

NOTE: See page 4.21 for 

dimensions. 

Fast Acting Ball Lock ® Shanks 

B 

B 

Table 

Table Slot 

A Slot Size A Size (mm) 

Part +0.000 +0.000 Part +0.000 +0.000 

Number -0.0005 -0.0005 C Number -0.013 -0.013 C 

39501 .625 1/2 1 39562 16 14 1 

39502 .625 9/16 1 39563 16 16 1 

39503 .625 5/8 1 39564 16 18 1 

39504 .625 11/16 1 39565 16 20 1-1/8 

39505 .625 3/4 1-1/8 39566 16 22 1-1/8 

39506 .625 13/16 1-1/8 

39507 .625 7/8 1-1/8 

NOTE: All shanks are 5/8" diameter 

Fast Acting 

Ball Lock ® 

Shank 

Diameter 

(mm) 

Fixture 

Plate 

Thickness 

(in.) 

Jergens Ball Lock ® Jergens Ball Lock ® 

Shank w/Jergens 

Shank 

Thumb Screw 

Adjustable Handle 

Part Number 

Part Number 

Assembly T-Screw Assembly Handle 

16 1/2 49607-S 43904 49607-H 34314 

3/4 49608-S 43904 49608-H 34315 

20 3/4 49601-S 43904 49601-H 34315 

1 49602-S 43905 49602-H 34316 

25 3/4 49611-S 43907 49611-H 34328 

1 49612-S 43908 49612-H 34329 

30 3/4 49621-S 43910 49621-H 34334 

1 49622-S 43911 49622-H 34335 

35 3/4 49631-S 43913 49631-H 34339 

1 49632-S 43913 49632-H 34339 

1-1/2 49633-S 43914 N/A 

2 49634-S 43914 N/A 

Thumb 

Screw 

Adjustable 

Handle 

• Fast acting thumb 

screws 2 1/2 turns. 

No tools needed. 

• Handle can be 

moved out of the 

work area to avoid 

interference. 

1.20 



Multi-Purpose Subplate 

1000x500 Multi-Purpose Subplate 

Part Number Wt. (kg) 

59112 130 

The Jergens Multi-Purpose Subplate 

accommodates a wide variety of fixture plates and 

vises. This versatility facilitates using the same 

VMC for diverse products in repetitive runs-long 

and short batch sizes. 


58706 

58801 

69406 


METRIC DIMENSIONS 

1M 

• FreMax TM 15 Steel or Equivalent 

• Thickness: 31.75mm ±0.13mm 

• Parallel within 0.025mm 

58713 or 58715 

58727 

59112 

425 425 

300 300 


BUSHINGS I NSTALLED 

16MM BORED HOLE 

FOR SINE FIXTURE KEYS 

(2) PLACES 


BUSHINGS I NSTALLED 

Fixture Plate Options for Multi-Purpose Subplates – Aluminum or Steel 

1000 

Number of Fixture Receiver Required Number 

Plates/Vise That Mount Bushing Receiver Ball Lock ® of Shanks 

Fixture Plate*/Vise Thickness of on Multi-Purpose Center Bushing Shank Required Per 

Part Number Fixture Plate Subplate Distance Size Part Number Fixture Plate/Vise 

200 

150 

300 

425 

500 

METRIC PRE-MACHINED FIXTURE/SUBPLATES 

58713 (350 x 350) 20mm 2 300 x 300 20 mm 49651 4 

Fixture Plate 

58715 (400 x 400) 20mm 2 300 x 300 20 mm 49651 4 

Fixture Plate 

58801 (400 x 400) 30mm** 2 300 x 300 20 mm 49652 4 

Modular Grid Plate 

58706 Jigsaw 20mm 4 300 x 200 20 mm 49651 3 

Interlocking Plate 

58727 (500 x 500) 25mm 2 425 x 425 25 mm 49662 4 

Fixture Plate 

69406 20mm 4 300 x 200 20 mm 49651 3 

150mm Jigsaw Vise 

* See next page for dimensional data on fixture plates. Part numbers shown for aluminum plates, also available in steel. 

** Counterbored to 25mm at mounting holes. 


1M BALL LOCK ® MOUNTING SYSTEM 


Fixture Plates for Use on Multi-Purpose Subplate 

350x350x20mm Fixture Plate 


400x400 Modular Grid Fixture Plate 



58713 6 

Steel Plate 


58813 19 



58801 38 

400x400 Fixture Plate 



58715 8 


• Thickness: 20mm ±0.13mm 

• Parallel within 0.025mm Steel 

• Mounts to subplates with BallLock ® Shank 49651 (20x20mm) 

300 

Steel Plate 


58815 25 

• FreMax 15 Steel or equivalent 



(2) 20MM 


INSTALLED 


FOR HOLDDOWN 

(2) PLACES 

16MM X 6MM DEEP 

COUNTERBORE 

M12 X 1.75 

TAPPED HOLE 


300 

150 


FOR HOLDDOWN 

(2) PLACES 



(2) PLACES 

(2) 20MM 


INSTALLED 

Jigsaw Interlocking FixturePlate 



58706 4 

Steel Plate 


58806 12 

• Material: Cast Aluminum or FreMax 15 Steel or equivalent 



• For use with narrow base 100mm or 150mm vise models 

• Design allows close spacing of vises for more parts per run 

• Mounts to Subplates using Ball Lock ® Shank 44651 (20x20mm) 

• Useful for high density fixturing 

300 

400 

50 

TYP 




58727 17 




• Mounts to Subplates using Ball Lock ® Shank 49662 (25x25mm) 

500 

425 

300 

400 

Mounts to Subplate 

with BallLock ® Shank 

49652 (20x25mm) 

Steel Plate 


58827 48 

CLEARANCE HOLE FOR 

HOLDDOWN 

500 425 


FOR HOLDDOWN 

(2) PLACES 



(2) PLACES 

250 

200 

(2) 20MM 


INSTALLED 

300 

150 

200 

212.50 

(2) 25MM 


INSTALLED 

400 

1.22 




Pre-Machined Ball Lock ® Steel Subplate 



1M 

400 

400 x400 Subplate 

300 


59101 37 

(4) 20MM 

FACE MOUNT BUSHINGS 

INSTALLED 

Equipped with four 20mm receiver bushings for use with 

350x350 or 400x400 (mm) fixture plates. Ideal for horizontal 

machining centers or multiple pallet machining centers. 

400 

300 

150 



(2) PLACES 

• FreMax 15 steel plate or equivalent 



250 

25 

650 

325 

650x400 Dual Station Subplate 


59111 58 

400 

300 

150 



(2) PLACES 

Aluminum Steel Plate Number Plate 

Plate Part Part of Fixture Width and 

Number Number Plates Length (mm) 

58713 58813 1 350x350 

58715 58815 1 400x400 

58711 58811 2 300x350 

150 

300 

(12) 20MM 

FACE MOUNT BUSHINGS 

INSTALLED 

Equipped with twelve installed 20mm receiver 

bushings to easily locate and mount Jergens 

Standard Fixture Plates. 

• Ideal for vertical machining centers 



58713 or 

58715 

58711 

59111 


20 

˚˚˚ 

˚ 

16mm Bored Holes For 


(2) Places 

12mm Dia. For Mounting To 

Table (4) Places 

(4) 16mm Face Mount 

Bushings Installed 

300 

˚˚˚ 

63.5 

200 250 

63.5 

˚ 

250x375 Bridgeport - Style Subplate 


59121 15 

Equipped with four installed 16mm receiver bushings and 

12mm mounting holes. Used with the Bridgeport style 

fixture plates 58731 or 58831. 



375 

Ball Lock ® Quick Change Kits include all components needed in a single package. See page 1.25 for details. 




Ball Lock ® Fixture Plates 

• Cast Aluminum; or FreMax 15 Steel or equivalent 

• Thickness ±0.13mm 

• Parallel within .025mm Steel 

• 6061–T-651 plates, flat within 0.03mm available upon request 

Ball Lock ® Fixture Plates with 2 Primary Liners Installed 

Part Number 

Weight 

Weight 

Aluminum (Kgs) Steel (Kgs) 

Plate 

Dimensions 

(mm) 

Plate 

Thickness 

±0.13(mm) 

Ball Lock ® 

Shank Size 

(mm) 

Ball Lock ® 

Shank Part 

Number 

58706 4 58806 12 250 x400 20 20 49651 

58711 5 58811 16 300 x350 20 20 49651 

58713 6 58813 19 350 x 350 20 20 49651 

58715 8 58815 25 400 x 400 20 20 49651 

58727 17 58827 48 500 x 500 25 25 49662 

58801 38 400 x 400 28.57 20 49652 

58731 5 58831 15 375x250 20 16 49657 


• Machined to close tolerances 

• Repeatability ±0.013mm or better 

• Reduces fixture set-up and 

assembly time 

• Provided with 16mm bored holes 


• For horizontal or vertical 

machining centers, Tool Room 

Mills machines, or multiple pallet 

machining centers 


Custom Sizes Available 

Jergens will make Ball Lock ® fixture plates or subplates to your 

specifications. Call 1-216-486-5540 for further information. 

375x250x20mm Fixture Plate Bridgeport Style 



58731 5 

Steel Plate 


58831 15 




58711 5 

Steel Plate 


58811 16 

Clearance Hole For 


300 

250 

100 

16mm Bored Holes For 


(2) Places 



300 

375 

200 

250 

350 300 

150 

Clearance Holes For 


16mm Bored Holes 

For Sine Fixture Keys 

(2) Places 



1.24 






1M 


The Jergens Ball Lock ® Quick Change Kits speed fixture changeover in 

all types of manufacturing operations. Each kit includes two aluminum 

fixture plates with 2 primary liner bushings installed; one steel subplate 

with receiver bushings installed, and four 20mm Ball Lock ® shanks 

with working loads of 3000 lbs. each. While one fixture plate is on the 

machine, the operator can load parts on the other. This minimizes 

downtime for true set-up reduction. To enable the subplate to be 

mounted on a slotted table without the need to indicate the subplate, 

sine fixture keys can be used. The sine fixture key reamed holes are 

oriented parallel to the receiver bushings on the subplate and to the 

liner bushings on the fixture plate. These also allow the fixture plate 

to be mounted on a toolroom mill 

without the need to indicate it. This 

is extremely useful when machining 

location points on your fixture. 

Everything You Need to Change Fixtures in Less Than One Minute 

Aluminum 

Fixture Plate 

16mm Bored 

Hole for Sine 

Fixture Keys 

20mm Ball Lock ® 

Shank 


Part No. 

Kit Includes 

59002 2 - 58715 (400x400x20) aluminum 



1 - 59101 (400x400x25) steel subplate 


4 - 20mm Ball Lock ® Shanks (49651) 


Steel Subplate 

16mm Bored 

Hole for Sine 

Fixture Keys 

(2) 20mm Primary Liner 

Bushings Installed 

(4) 20mm 

Receiver 

Bushings 

Installed 

Custom Kits Available 

Jergens manufactures ready to use kits including 

Ball Lock ® subplate and fixture plates. 

For a special kit tailored to your CNC machine, 

please provide: 

Name and Type of Machine __________________ 

Travel of Machine Table (x, y, z) ______________ 

Dimensions of Machine Table (x and y) _________ 

Maximum Weight allowed on Machine Table _____ 

T-slot Width and Center to Center Distance _____ 




Pre-Machined Ball Lock ® T-Columns 



• Ball Lock ® Receiver Bushings and Liners installed 


• Perpendicularity is 0.025 mm per 250 mm 


Fixture 

Plate 




Call 1-216-486-5540 for design specification information. 

Subplate 

Tooling 

Column 

METRIC PRE-MACHINED TOOLING COLUMNS 

Cast Iron T-Columns With 



Size (mm) Number C D E F G H I J K L M N (mm) (mm) (kg) 

400 69151 410 25 400 400 350 350 350 350 100 500 125 90 20 20 190 

500 69161 560 25 500 500 475 425 425 425 120 650 137.5 90 25 25 310 

630 69171 660 40 630 630 575 550 525 525 100 750 137.5 90 35 25 500 

M12 

See page 1.28 for Metric Fixture Plates and Subplates 

*Note: Window sections are also available on T-Columns. Specify window size and location (Q and R Dimensions). 





400 69151 58717 58817 400 x 400 49651 20 x 20 59102 49652 20 x 25 

500 69161 58745 58845 500 x 550 49662 25 x 25 59103 49662 25 x 25 

630 69171 58746 58846 625 x 650 49662 25 x 25 59104 49683 35 x 40 





1.26 






1M 

Pre-Machined Ball Lock ® 4-Sided Tooling Columns 

• Class 40 cast iron 


• Ball Lock ® Receiver Bushings and Liner Bushings installed 


• Perpendicularity is 0.025 mm per 250 mm 

Tooling 

Column 

Fixture 

Plate 




Call 1-216-486-5540 for design specification information. 

Subplate 

Cast Iron 4-Sided Tooling Columns With 


See page 1.26 for Metric Fixture and Subplates 


Size (mm) Number A B C D E F G H I J K L M N (mm) (mm) (kg) 

400 69051 250 250 505 25 400 400 450 150 350 350 40 600 125 95 20 20 225 

500 69061 300 300 630 25 500 500 550 175 425 425 40 725 137.5 95 25 25 320 

630 69071 400 400 655 40 630 630 575 275 525 525 45 750 137.5 95 35 25 495 

M12 

METRIC PRE-MACHINED TOOLING COLUMNS 





400 69051 58741 58841 250 x 500 49651 20 x 20 59102 49652 20 x 25 

500 69061 58742 58842 300 x 625 49662 25 x 25 59103 49662 25 x 25 

630 69071 58743 58843 400 x 650 49662 25 x 25 59104 49683 35 x 40 



Product improvement is a continuing process at Jergens. Specifications and engineering data are subject to 

change after publishing. Contact Jergens Technical Sales Department to verify any dimensions or specifications. 




Subplates for Tooling Columns and Fixture Plates 

16mm Bored holes 



Receiver 

Bushings 

A 

B 

Standard Steel Subplates for Tooling Columns 

Subplate Mounting holes can be provided per customer specification. 

Supplied with Ball Lock ® Receiver Bushings installed. 


Ball Lock ® Pattern Receiver Thickness of 

Part Pallet Size For Tooling A B Size Subplate Wt 

Number (mm) Columns (mm) (mm) (mm) (mm) ±0.13 (Kgs) 

59102 400 69151/69051 350 350 20 28.57 31 

59103 500 69161/69061 425 425 25 31.75 59 

59103-C* 500 69151, 69051 350/425 350/425 20/25 31.75 59 

69161, 69061 Dual Dual Dual 

59104 630 69171/69071 525 525 35 34.92 124 




(2) places 

Primary 

Liners 



(2) places 

J 

E 

Primary 

Liners 

Fixture Plates for Standard Tooling Columns and T-Columns 


Fixture Fixture Plate Ball Lock ® Pattern Liner 

Pallet Part Number For Tooling Plate Size Thickness H G Size 

Size (mm) Aluminum (kg) Steel (kg) Columns Type (mm) (mm) ±0.13 (mm) (mm) (mm) 

400 58741 7 58841 19 69051 4-S 250x500 150 450 20 20 

I 

500 58742 13 58842 36 69061 4-S 300x625 175 550 25 25 

630 58743 18 58843 50 69071 4-S 400x650 275 575 25 25 

400 58717 8 58817 25 69151 T 400x400 350 350 20 20 

500 58745 19 58845 53 69161 T 500x550 425 475 25 25 

630 58746 27 58846 63 69171 T 625x650 550 575 25 25 

F 

Fixture Plates for Tooling Column Subplates 


Ball Lock ® 

Pallet Part Number Plate Dim. Fixture Plate Pattern Liner 

Size For E F Thickness I J Size 

(mm) Aluminum (kg) Steel (kg) Subplate (mm) (mm) ±0.13 (mm) (mm) (mm) (mm) 

400 58717 8 58817 25 59102 400 400 20 350 350 20 

500 58727 17 58827 48 59103 500 500 25 425 425 25 

630 58732 27 58832 76 59104 630 630 25 525 525 35 


( mm ) 

0.0015 

0.00125 

0.001 

0.00075 

0.0005 

0.00025 

0 

0 

Aluminum and Steel Expansion 

(per cm ) 

2.8 5.4 8.4 11.2 14 16.8 

Change in Degrees C 

NOTE: Aluminum and steel expand at different rates. Please take this information into consideration 

when creating your own Ball Lock ® fixture and subplates. 

1.28 




Ball Lock® For 4th Axis Rotary Indexers 

Problem: 

Rotary indexers increase the versatility of vertical machining 

centers, yet they offer one major challenge: set-up is so timeconsuming 

that it may limit a machine’s flexibility. In many cases, 

machinists dedicate their 4th Axis tool to a single machine to 

avoid the agony of an extended set-up and changeover. 

Benefits: 

• Maximize indexer utilization 

• Eliminate lengthy set-ups 

• Accurate fixture plate changover in seconds 



1M 

Jergen’s Solution: 

Ball Lock ® Mounting System for Indexers provides a double 

solution. 

First, Ball Lock ® mounting plates free up your machine for 

additional work by allowing a fast and accurate installation 

and removal of the complete indexer. Avoid hours of set up. 

The Ball Lock ® System does it in minutes, with repeatability at 

±.0005" (±.013mm). Low profile, positive clamping, proven in 

over many years of field use. 

Second, the Ball Lock ® System provides your fixture plate 

changeover. By mounting the round subplate to the indexer 

faceplate, you’ll “plug-in” new fixtures in record time 

(less than 60 seconds). 

Indexer Face Plate 

Ball Lock ® 

Fixture Plate 

For Holding 

Production 

Workpiece 

Ball Lock ® 

Shanks 

Ball Lock ® 

Subplate 


Workpiece 

Ball Lock ® Fixture Plate 

For Mounting Indexer 

to Subplate and 

Machine Table 

Subplates and fixture plates come with bushings pre-installed. 





Round Ball Lock ® Fixture Plates and Subplates 

Standard Round 

Cast Aluminum, FreeMax or Steel equivalent 

Fixture Plate (mm) 

Part Ball Lock ® Ball Lock ® Weight 

No. A B Thickness Liner Shank (Kgs) 

58707 200 150 20 16 49657 1.6 

58708 250 200 25 20 49652 3.2 

58709 300 250 25 20 49652 5.0 

Subplate(mm) 

Part Ball Lock ® Center Weight 

No. A B Thickness Receiver Hole (Kgs) 

59107 200 150 20 16 25 5.0 

59108 250 200 25 20 50 9.6 

59109 300 250 25 20 50 15.0 

Note: Equivalent system available in inch dimensions. 

Custom Round Plates 


Indexer: 

Make: 

Model: 

Diameter: 

Light Duty or Heavy Duty: 

Through Hole Bore: 

CNC Machine: 

Make: 

Model: 

Weight Capacity: 

Indexer Faceplate: 

T-Slot Size: 


or 

Drilled Tapped Hole Size: 



Product improvement is a continuing process at Jergens. Specifications and engineering data are subject to change without 

notice. If current information is critical to your design, it is suggested that you contact Jergens Technical Sales Department to 

verify any dimensions or specifications. 

1.30 




Locating and Clamping Shanks 



1M 

U.S. Patents: 3,498,653 

4,135,418 

Replacement Kits 

Locating and Clamping Shank Dimensions 

Shank 

Diameter 

(mm) 

A 

13 

16 

20 

25 

30 

35 

50 

Fixture 

Plate 

Thickness 

±0.13mm 

13 

20 

20 

25 

20 

25 

20 

25 

20 

25 

20 

25 

40 

50 

20 

25 

40 

50 

• Material: Shank/Bushing, AISI 4340 

Liner, 52100 

• Finish: Black Oxide 

• Heat Treat: Shanks, RC 40-45 

Bushings, RC 50-54 

Liners, RC 62-64 

• Operating Temperature Range: 

-30°C to 200°C 

• Stainless Steel available 

Head of Shank 

Shank 

Part 

Height Diameter 

Number B C D 

49655 

49656 

49657 

49658 

49651 

49652 

49661 

49662 

49671 

49672 

49681 

49682 

49683 

49684 

49691 

49692 

49693 

49694 

6 

8 

10 

10 

13 

13 

20 

22 

32 

40 

45 

50 

60 

75 

Each Kit Includes: 

• Replacement Screw 

• Locking Balls 

• Drive Ball 

• O-Ring 

27.6 

34.6 

36.5 

41.5 

39.5 

44.5 

44.0 

49.0 

49.0 

54.0 

51.0 

56.0 

71.0 

81.0 

64.0 

69.0 

84.0 

94.0 

Hex 

Wrench Size 

For 

Set Screw 

2.5 

3 

3 

4 

5 

6 

10 

D 

C 

A 

Any Ball Lock ® application requires at least two sets of 

shanks, receiver bushings and liners. The liners are 

placed into the fixture plate to insure extremely accurate 

positioning. If more than two shanks are required (to 

provide additional hold down force), omit the liner bushing 

so that these additional holes will not interfere with your 

primary locating holes. 

See page 1.33 for Fast Acting Shanks. 

Maximum 

Screw Holddown 

Torque Force 

(N.m) (KN) 

1.2 3.3 

4.5 

5.3 

11 

18 

33 

65 

5.3 

13.3 

30 

44 

68 

88 

B 

Recommended 

Screw Holddown 

Torque Force 

(N.m) (KN) 

1 2.7 

3 

4 

9 

15 

25 

50 

3.5 

10 

23 

35 

52 

67 

Shank 

Repair Kit 

Part 

Number 

49955 

49956 

49957 

49958 

49951 

49952 

49961 

49962 

49971 

49972 

49981 

49982 

49983 

49984 

49991 

49992 

49993 

49994 

METRIC BALL LOCK ® COMPONENTS 




Receiver Bushings 


Two styles of receiver bushings are available. Installed bushings should be approximately 0.3mm below subplate surface. 

Max. Corner 

Radius 0.5mm 

Face Mount 

Back Mount 

Max. Corner 

Radius 0.5mm 

H - Tap 3 Holes 

Equally Spaced 

On Bolt Circle Dia. 






Generally, the face mount receiver bushing is utilized in blind hole 

applications (Slip Fit). 

Installation Dimensions 

Face Mount 

Shank 

Dia. 

(mm) 

13 

16 

20 

25 

30 

35 

50 

Face 

Mount 

Part 

Number 

49556 

49557 

49551 

49552 

49553 

49554 

49555 

Actual 

O.D. 

-0.01 

-0.02 

35 

37 

45 

55 

60 

70 

92 

Clearance 

Drill 

Diameter 

E 

13.5 

21.0 

21.0 

25.5 

30.5 

40.0 

55.0 

Bore 

+0.010 

+0.003 

F 

35 

37 

45 

55 

60 

70 

92 

1 

Cap Screws Supplied with Face Mount Bushings. 

Liner Bushings for 

Fixture Plates 

Depth 

+0.025 

-0.025 

G 

11.91 

11.91 

16.21 

20.32 

22.15 

22.99 

31.50 

Note on Installation of Press Fit Liners & 

Back Mount Style Receiver Bushings: 

To alleviate the possibility of binding the 

shank in the bore, the maximum interference 

fit between bore and bushing O.D. should not 

exceed 0.013 mm. 

Tap 

Size & 

Depth 1 

H 

M4x0.7 x 7 

M4x0.7 x 7 

M5x0.8 x 9 

M6x1.0 x 10 

M6x1.0 x 11 

M8x1.25 x 17 

M10x1.5 x 18 

Locating repeatability will determine if one primary 

and one secondary or two primary liners are needed. 

With two primary liners, repeatability of ±0.013 mm can 

be maintained if the two holes for receiver bushings are 

held to a centerline distance of ±0.005 mm tolerance. 

Bolt Circle 

Diameter 

3 PL Equally 

Spaced 

25 

29 

35 

42 

48 

56 

75 

Min. 

Subplate 

Thickness 

D 

20 

20 

25 

30 

35 

40 

50 

Liner Dimensions 

Shank 

Diameter 

(mm) 

13 

16 

20 

25 

30 

35 

50 

Fixture Plate 

Thickness 

+0.13 

- 0.13 

13 

20 

20 

25 

20 

25 

20 

25 

20 

25 

20 

25 

40 

50 

20 

25 

40 

50 

The back mount receiver bushing is used in through hole 

applications (Light Press Fit). 

Back Mount 

Shank 

Dia. 

(mm) 

13 

16 

20 

25 

30 

35 

50 

49755 

49756 

49757 

49758 

49751 

49752 

49761 

49762 

49771 

49772 

49781 

49782 

49783 

49784 

49791 

49792 

49793 

49794 

Back 

Mount 

Part 

Number 

49566 

49567 

49561 

49562 

49563 

49564 

49565 

Primary Liner 

Part Number 

I.D. 

13.01 

16.01 

20.01 

25.01 

30.01 

35.01 

50.01 

Actual 

O.D. 

+0.04 

+0.03 

A 

20 

22 

28 

35 

42 

48 

67 

49855 

49856 

49857 

49858 

49851 

49852 

49861 

49862 

49871 

49872 

49881 

49882 

49883 

49884 

49891 

49892 

49893 

49894 

Depth 

+0.025 

-0.025 

B 

6.92 

7.24 

8.74 

10.54 

10.95 

12.50 

15.75 

Secondary Liner 

Part Number 

I.D. 

13.04 

16.04 

20.04 

25.04 

30.04 

35.04 

50.04 

C-Bore 

± 0.15 

C 

26 

29 

33 

41 

49 

55 

76 

Min. 

Subplate 

Thickness 

D 

20 

20 

25 

25 

30 

35 

45 

Liner O.D. 

+0.00 

- 0.01 

19.040 

19.040 

25.042 

25.042 

35.042 

35.042 

35.042 

35.042 

45.042 

45.042 

45.042 

45.042 

45.042 

45.042 

63.546 

63.546 

63.546 

63.546 

1.32 



Accessories 

Tapered Caps 

and Plugs 

Keep debris out of your 

subplate’s receiver 

bushings when not in 

use. Polyethylene caps 

snap in and out easily. 

Packaged 

10 per 

pack. 


Receiver 

Bushing Part 

Diameter Number 

13 49201 

16 49202 

20 49203 

25 49204 

30 49205 

35 49206 

50 49207 



Lifting Handles 

For easy handling of fixture plates up 

to 500 lbs. 

1M 

Part Number Length Ht. W Mounting Distance 

33701 107mm 36mm .38kg 93.47mm 


Shank Slot 

Part Size Size Wt. 

Number A B C (kg) 

39551 16 12 25 .04 

39552 16 14 25 .05 

39553 16 16 25 .05 

39554 16 18 29 .05 

39555 16 20 29 .06 

39556 16 22 29 .06 

39557 20 24 35 .07 

39558 20 28 35 .10 

39559 20 32 40 .10 

Recommended 

Hole Diameter 

16mm Shank Size: 

16.01 ± 0.01 

20mm Shank Size: 

20.01 ± 0.01 

Locate subplates or fixture plates to 

slotted machine tables without having 

to slot the plate. Available in sizes from 

12mm to 32mm slots. 




Ball Lock ® 

Shank 

Diameter 

(mm) 

Fixture 

Plate 

Thickness 

(mm) 

Shank with 

Thumb Screw 

Shank with 

Adjustable Handle 

Part Number 

Part Number 

Assenbly T-Screw Assenbly Handle 

13 13 49655-S 43971 49655-H 34360 

20 49656-S 43972 49656-H 34361 

16 20 49657-S 43974 49657-H 34365 

25 49658-S 43975 49658-H 34365 

20 20 49651-S 43974 49651-H 34365 

25 49652-S 43975 49652-H 34365 

25 20 49661-S 43977 49661-H 34378 

25 49662-S 43978 49662-H 34379 

30 20 49671-S 43980 49671-H 34385 

25 49672-S 43980 49672-H 34385 

35 20 49681-S 43985 49681-H 34393 

25 49682-S 43985 49682-H 34393 

Thumb 

Screw 

Adjustable 

Handle 

• Fast acting thumb 

screws 2 1/2 turns. 

No tools needed. 

• Handle can be 

moved out of the 

work area to avoid 

interference. 


1 ZERO POINT MOUNTING SYSTEM 

Features of the Jergens Zero-Point Mounting System 

• Positioning and clamping in one operation 

• High repeatability and accuracy 

• Low cost solution for quick pallet changing 


Typical applications for the 

Jergens Zero-Point System: 

• Milling 

• Assembly 

• Welding 

• Injection Molding 

• Grinding 

• Measuring 

Pull Studs can also be 

installed directly into the 

workpieces, making 5-sided 

processing possible. 

Best results with large and 

heavy workpieces. 

Jergens Zero-Point clamping 

systems are made exclusively 

of rust-free materials and so 

are ideally suited for use in 

the food-service area as well 

as in the pharmaceutical and 

chemical industry. 

Through different dimensions, 

the advantage of the Zero- 

Point clamping system are 

optimally used. 

1.36 



ZERO POINT MOUNTING SYSTEM 

1 

Pull Studs and Engagement Screws 

Pages 1.42-1.43 

Clamping Plates with Built-In Modules 

Pages 1.40-1.41 

Threaded Clamping Modules 

Pages 1.44-1.45 

• Machine tables 

• Plates 

• 4-axis/5-axis machining 

• Columns 

• Pallets 

Raised/Mounted Clamping Modules 

Pages 1.46-1.47 

• For large & heavy workpieces 

• Pull Studs installed 

directly into workpiece 

Flange Type Module 

Page 1.49 

• Used to fasten surface-mounted clamping modules 

on the machine table 

• Hydraulic release with or without blowout 

Horizontal Rapid-Clamping Module 

Page 1.50 

• For easy handling of heavy fixtures 



Jergens’ Zero-Point Mounting System – 

Cut Set-up Times by Up to 90%. 

Fix, Position and Clamp in a Single Step with 

Jergens’ Zero-Point Mounting System. 


Jergens is proud to introduce the best-engineered Zero-Point 

Mounting System (ZPS) on the market. This revolutionary 

technology cuts set-up time by up to 90% by combining fixing, 

positioning and clamping in a single operation. Available with 

either pneumatic or hydraulic release, these positive locking 

locating modules allow operators to quickly change out large 

and small machine fixtures with extreme accuracy and minimal 

effort. Other features include: 

• Repeatability



1 

Mechanical Locking System 

Experience high holding force without the need to maintain 

hydraulic pressure. 

Large Ball Diameter 

Provides increased strength and even load distribution. 

No Ball Cage 

Free movement of the bearing balls reduces friction. 

Form Fit Ball Channel 

Tapered contact areas eliminate point loads and 

reduce failures. 

Three-Point Load Distribution 

Equal load spacing optimizes force distribution. 

Integrated Safety System 

Process-sure clamping module can always be opened, 

eliminating the need to forcibly remove modules if a failure 

should occur. 



Clamping and Positioning 


On each fixture use: 

• 1 - Zero-Point Pull Stud 

• 1 - Timing Pull Stud 

• The Zero-Point and Timing Stud should 

be perpendicular 

• Use any combination of clearance and/or 

protection Pull Stud 

ZERO POINT PULL STUD 

CLEARANCE PULL STUD 

FOR HOLD DOWN 

CLEARANCE PULL STUD 

FOR HOLD DOWN 

TIMING PULL STUD 

Dimensions for machining pull stud mountings 

Size ØD1 ØM S1 S2 

K5 10 M6 2.5 12 

K10 15 M8 3.5 16 

K20 25 M12 5.5 23 

K40 25 M16 5.5 30 

Note: 

• Pull Stud with internal thread for clamping from above 

• Pull Studs with different diameter D1, preventing interchange of the 

Zero-Point, timing and clearance Pull Stud during installation. 

• Pull Stud for series production, (notch type), Floating Pull Stud for 

compensation of thermal expansion 

• Automatic lifting of the pallet / fixture 

Figure: 

Shown with Pull Stud and engagement screw 

1.40 



2-Way Clamping Station 

Hydraulic Unlocking 

Repeatability < 0.005 mm (0.0002") 


1 

Part 

Pull-In/Locking Force 

Number Size up to kN / (lbs) A B HA K L L1 ØN R S SM kg 

303289 20 2 x 20 / (2 x 4500) 196 396 10 19 45 180 20 G1/4 46 200 21.9 

303297 40 2 x 40 / (2 x 9000) 296 546 15 26 57 250 25 G1/4 61 320 59.5 

All linear dimensions in (mm) 

Note: On request, we can incorporate mounting holes to your requirements in the base plate. Other dimensions, gauges and number of clamping module layouts on request. 

4-way clamping Station 



Part Size Pull-In/Locking Force 

Number up to kN / (lbs) A B HA K L L1 ØN R S SM kg 

303321 20 4 x 20 / (4 x 4500) 396 396 10 18 148 180 20 G1/4 46 200 44.0 

303339 40 4 x 40 / (4 x 9000) 546 546 15 26 217 250 25 G1/4 61 320 110.0 


Note: On request, we can incorporate mounting holes to your requirements in the base plate. Other dimensions, gauges and number of clamping module layouts on request. 



Pull Studs 

K5 Modules 

Hardened Stainless Steel, for hydraulic and 

pneumatic clamping modules 


Zero Point Timing Clearance 

Protection Pull Stud 

Part 

Number Size Description ØDN ØD1 ØD2 H H1 M T g 

306019 K5 Zero-Point Stud 15.0 10 6 12.7 10.2 - 2.5 15 

306035 K5 Timing Stud 15.0 10 6 12.7 10.2 - 2.5 15 

306050 K5 Clearance Stud 14.8 10 6 12.7 10.2 - 2.5 15 

306076 K5 Protection Plug 14.8 - - 10.2 - M 6 8.0 12 

K10 Modules 

Hardened Stainless Steel, 

for hydraulic and pneumatic 

clamping modules 

Part 


303610 K10 Zero-Point Stud 22.0 15 8 19 16 - 3 30 

303636 K10 Timing Stud 22.0 15 8 19 16 - 3 30 

304519 K10 Clearance Stud 21.8 15 8 19 16 - 3 30 

304535 K10 Protection Plug 21.8 - - 16 - M 8 12 30 

K20 Modules 




K40 Modules 




Part 



303156 K20 Timing Stud 32.0 25 12 28 23 - 5 110 


303172 K20 Protection Plug 31.8 - - 23 - M8 16 110 

Part 



303198 K40 Timing Stud 40.0 25 16 34 29 - 5 180 


303214 K40 Protection Plug 39.8 - - 29 - M8 20 180 

1.42 



Engagement Screws 

Strength class 10.9 

For installation and surface mounted clamping modules 


1 

Part 

Number Size M L L1 g 

306092 K 5 M 6 25 3.4 18 

303578 K10 M 8 37 6.0 30 

303222 K20 M12 54 9.0 70 

303230 K40 M16 69 10.0 130 

Horizontal Engagement Screws 

Strength class 10.9 

For horizontal rapid clamping cylinder on page 1.46 

Part 

Number Size M L L1 g 

303248 K20 M12 56 10.5 100 

303255 K40 M16 73 13.0 200 




Threaded Clamping Modules (K5) 

Round, Screw-In Version 


Cover and piston hardened. 


With a small footprint for installation in base 

plates, machine tables, clamping profiles, 

columns and towers, swivel bridges, machine 

pallets and clamping pallets. 

• Installation diagrams on request 

Hardened Stainless Steel 

Part Size Pull-In/Locking Holding Force 

Number Force up to kN / (lbs) kN / (lbs) ØD ØDN ØD1 H HA ØLK T g 

305953 K5 5 / (1100) 13 / (2900) M45 x 1 15 39 19.8 5.8 36 14 300 


Note: Threaded clamping module with a low installation height of 19.8 mm and an installation diameter of 45 mm (M45 x 1). 

Hydraulic supply and pressure is only needed for unclamping (min. 50 bar / 725psi, max. 60 bar / 870psi). The threaded clamping module is mechanically locked 

in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. Further more, there are no 

cumbersome lines or dangers of leakage. The contact surface is the upper surface of the housing. The hydraulic design has 1 connection: 1 x unclamping 

Round, Screw-in Version 

Pneumatic Unlocking 





columns and towers, swivel bridges, 

machine pallets and clamping pallets. 

Pneumatic modules are optimally suited for 

use in the food, pharmaceutical and 

chemical industries, as well as in oil-free 

applications. 



Part Size Pull-In/Locking Holding Force 

Number Force up to kN / (lbs) kN / (lbs) ØD ØDN ØD1 H HA ØLK T g 

305979 K5 1.5 / (330) 13 / (2900) M45 x 1 15 39 19.8 5.8 36 14 300 


Note: Threaded clamping module with a low installation height of 19.8 mm and an installation diameter of 45 mm (M45 x 1). 

Pneumatic pressure is needed for unclamping ( min 8 bar/ 116 psi, max 12 bar/ 175 psi). For clamping process pneumatic pressure of min 5 bar / 75 psi, max 6 

bar / 90 psi is required briefly in order to achieve defined pull-in force. The threaded clamping module is mechanically locked in the clamped position. The unique 

mechanical locking system results in virtually no vibration even with extensive machining forces. Further more, there are no cumbersome lines or dangers of leakage. 

The pneumatic design has 2 connections: 1 x unclamping / 1 x clamping. 

1.44 




Threaded Clamping Modules (K10, K20, K40) 

Round, Hydraulic Unlocking 



With a small foot-print for installation in 

base plates, machine tables, clamping 

profiles, columns and towers, swivel 

bridges, machine pallets and clamping 

pallets. 


1 


Part Pull-in/locking Holding force 

Number Size force up to kN / (lbs) kN / (lbs) Blow out ØD ØDN ØD1 H HA ØLK M T kg 

303628 K10 10 / (2250) 25 / (5620) - 78 22 50 30 7 60 M5 23 0.45 

305367 K10 10 / (2250) 25 / (5620) Yes 78 22 50 30 7 60 M5 23 0.45 

302984 K20 20 / (4500) 55 / (12350) - 112 32 78 44 10 88 M6 34 1.40 

302992 K20 20 / (4500) 55 / (12350) Yes 112 32 78 44 10 88 M6 34 1.40 

303024 K40 40 / (9000) 105 / (23600) - 148 40 102 57 15 118 M8 42 3.45 

303032 K40 40 / (9000) 105 / (23600) Yes 148 40 102 57 15 118 M8 42 3.40 


Note: Threaded installation clamping modules have high holding and pull-in forces with very small installation dimensions. 

Hydraulic supply and pressure is only needed for unclamping (min. 50 bar / 725psi, max. 60 bar / 870psi). The threaded clamping module is mechanically locked in the 

clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. Further more, there are no cumbersome lines 

or dangers of leakage. The contact surface is the upper surface of the housing. The hydraulic design has 1 connection: 1 x unclamping 

Pneumatic Unlocking 





columns and towers, swivel bridges, 

machine pallets and clamping pallets. 



Part Pull-In/Locking Holding Force 

Number Size force up to kN / (lbs) kN / (lbs) Blow out ØD ØDN ØD1 H HA ØLK M T kg 

303602 K10 8 / (1800) 25 / (5620) - 78 22 50 30 7 60 M5 23 0.45 

305375 K10 8 / (1800) 25 / (5620) Yes 78 22 50 30 7 60 M5 23 0.45 

303008 K20 17 / (3800) 55 / (12350) - 112 32 78 44 10 88 M6 34 1.40 

303016 K20 17 / (3800) 55 / (12350) Yes 112 32 78 44 10 88 M6 34 1.40 

303040 K40 30 / (6700) 105 / (23600) - 148 40 102 57 15 118 M8 42 3.45 

303057 K40 30 / (6700) 105 / (23600) Yes 148 40 102 57 15 118 M8 42 3.40 


Note: The installation clamping modules have high holding and pull-in forces with very small installation dimensions. 

Pneumatic pressure is needed for unclamping ( min 8 bar/ 116 psi, max 12 bar/ 175 psi). For clamping process pneumatic pressure of min 5 bar / 75 psi, max 6 bar / 90 

psi is required briefly in order to achieve defined pull-in force. The installation clamping module is mechanically locked in the clamped position. The unique mechanical 

locking system results in virtually no vibration even with extensive machining forces. Further more, there are no cumbersome lines or dangers of leakage. The pneumatic 

design has 2 connections: 1 x unclamping / 1 x clamping. 




Raised/Mounted Clamping Modules (K5) 




For mounting on machine tables, clamping 

profiles, columns and towers, measuring 

machines, assembly stations. 


Stainless Steel 


Number Size Force up to kN / (lbs) kN / (lbs) ØB ØD ØDB ØDN HA K R g 

306159 K5 5 / (1100) 13 / (2900) 5.8 62 54 15 26 15 G1/8 300 


Note: Hydraulic supply and pressure is only needed for unclamping (min. 50 bar / 725psi, max. 60 bar / 870psi). The installation clamping module is mechanically 

locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. The contact surface is the 

upper surface of the housing. The hydraulic design has 1 connection: 1 x unclamping 

Round, Pneumatic Unlocking 





machines, assembly stations. 




Number Size Force up to kN / (lbs) kN / (lbs) ØB ØD ØDB ØDN HA K R g 

306175 K5 1.5 / (330) 13 / (2900) 5.8 62 54 15 26 15 G1/8 300 


Note: Pneumatic pressure is needed for unclamping ( min 8 bar/ 116 psi, max 12 bar/ 175 psi). For clamping process pneumatic pressure of min 5 bar / 75 psi, max 6 bar / 90 

psi is required briefly in order to achieve defined pull-in force. The installation clamping module is mechanically locked in the clamped position. The unique mechanical locking 

system results in virtually no vibration even with extensive machining forces. The pneumatic design has 2 connections: 1 x unclamping / 1 x clamping. 

1.46 




1 

Raised/Mounted Clamping Modules (K10, K20, K40) 






machines,assembly stations in connection 

with clamping bracket on page 1.48. 



Number Size Force up to kN / (lbs) kN / (lbs) Blow out ØD ØDB ØDN HA K R kg 

303487 K10 10 / (2250) 25 / (5620) - 78 77.5 22 30 16.50 G1/8 0.90 

303545 K10 10 / (2250) 25 / (5620) Yes 78 77.5 22 30 16.50 G1/8 0.90 

302828 K20 20 / (4500) 55 / (12350) - 112 110.0 32 50 28.25 G1/4 2.75 

302836 K20 20 / (4500) 55 / (12350) Yes 112 110.0 32 50 28.25 G1/4 2.70 

302869 K40 40 / (9000) 105 / (23600) - 148 146.0 40 62 32.50 G1/4 3.85 

302877 K40 40 / (9000) 105 / (23600) Yes 148 146.0 40 62 32.50 G1/4 3.80 


Note: Hydraulic supply and pressure is only needed for unclamping (min. 50 bar / 725psi, max. 60 bar / 870psi). The installation clamping module is mechanically 

locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. Further more, there 

are no cumbersome lines and no danger of leakage. The contact surface is the upper surface of the housing. The hydraulic design has 1 connection: 1 x unclamping 

Round, Pneumatic Unlocking 



For mounting on machine tables, 

clamping profiles, columns and towers, 

measuring machines,assembly stations 

in connection with clamping bracket on 

page 1.48. 



Number Size Force up to kN / (lbs) kN / (lbs) Blow out ØD ØDB ØDN HA K R kg 

303529 K10 8 / (1800) 25 / (5620) - 78 77.5 22 30 16.50 G1/8 0.90 

305193 K10 8 / (1800) 25 / (5620) Yes 78 77.5 22 30 16.50 G1/8 0.90 

302844 K20 17 / (3800) 55 / (12350) - 112 110.0 32 50 28.25 G1/4 2.60 

302851 K20 17 / (3800) 55 / (12350) Yes 112 110.0 32 50 28.25 G1/4 2.60 

302885 K40 30 / (6700) 105 / (23600) - 148 146.0 40 62 32.50 G1/4 6.45 

302893 K40 30 / (6700) 105 / (23600) Yes 148 146.0 40 62 32.50 G1/4 6.40 


Note: Pneumatic pressure is needed for unclamping ( min 8 bar/ 116 psi, max 12 bar/ 175 psi). For clamping process pneumatic pressure of min 5 bar / 75 psi, max 6 bar / 

90 psi is required briefly in order to achieve defined pull-in force. The installation clamping module is mechanically locked in the clamped position. The unique mechanical locking 

system results in virtually no vibration even with extensive machining forces. The pneumatic design has 2 connections: 1 x unclamping / 1 x clamping. 




Clamping Bracket for Raised/Mounted Clamping Modules 

Black Nitrided 

Clamping flanges are used to fasten 

raised/mounted clamping modules on 

the machine table. See page 1.47. 

• Special clamping flanges for various 

T-slot tables 

• Clamping flange and housing 

manufactured as a single piece 

Stainless Steel 

Part 

Pieces 

Number Size Per Module ØD ØDB H ØLK M g 

303495 10 2 114 77.5 7.75 94 8.5 180 

302901 20 2 164 110.0 13.00 136 11.0 400 

302919 40 2 202 146.0 16.00 172 13.0 550 


Flange Type Installation Modules 

Features: 

• Oil supply by pipes or manifolds 

• Integrated centering 

• Provided as assembled unit 

Benefits: 

• Simple design and manufacturing of adaptor plate 

• Weight saving due to less thickness for adaptor plate 

• Easy to adapt to existing mounting angles and cubes 

Installation comparison 

Standard Clamping Module 

Cover Ring 

Flange Type Module 

Oil 

Oil 

Installation Module 

Flange 

Oil Supply by Pipes 

Oil Supply by Manifold 

Base Plate 

No seal face needed 

centering only 

Sealing face 

O-ring 

1.48 




1 

Flange Type Installation Modules 

Hydraulic Release 





Number Size force up to kN / (lbs) kN / (lbs) Blow out ØDA ØDN ØD1 HA K ØLK M R T kg 

424069 K10 10 / (2250) 25 / (5620) - 100 22 67 24 9 90 M5 G1/8 5.9 1.35 

424085 K10 10 / (2250) 25 / (5620) Yes 100 22 67 24 9 90 M5 G1/8 5.9 1.35 

423947 K20 20 / (4500) 55 / (12350) - 136 32 100 35 13 124 M6 G1/8 8.9 3.75 

423962 K20 20 / (4500) 55 / (12350) Yes 136 32 100 35 13 124 M6 G1/8 8.9 3.76 

424127 K40 40 / (9000) 105 / (23600) - 180 40 120 45 15 163 M8 G1/8 11.9 4.97 

424143 K40 40 / (9000) 105 / (23600) Yes 180 40 120 45 15 163 M8 G1/8 11.9 4.97 


Note: Combines features of the Threaded Module and Raised/Mounted module. Especially designed when installation space is limited and base plate or angle plate has 

relatively thin dimensions. The positioning of the module is simple and accurate when using the precision flange diameter. Hydraulic supply is possible by manifolds or 

pipes/hoses. Hydraulic supply and pressure is only needed for unclamping (min. 50 bar / 725psi, max. 60 bar / 870psi). The module is mechanically locked in the clamped 

position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. The hydraulic design has 1 connection: 1 x unclamping 

Pneumatic Release 





Number Size force up to kN / (lbs) kN / (lbs) Blow out ØDA ØDN ØD1 HA K ØLK M R T kg 

424101 K10 8 / (1800) 25 / (5620) - 100 22 67 24 9 90 M5 G1/8 5.9 1.35 

423988 K20 17 / (3800) 55 / (12350) - 136 32 100 35 13 124 M6 G1/8 8.9 4.97 

424168 K40 30 / (6700) 105 / (23600) - 180 40 120 45 15 163 M6 G1/8 11.9 4.97 


Note: Combines features of the Threaded Module and Raised/Mounted module. Especially designed when installation space is limited and base plate or angle plate has 

relatively thin dimensions. The positioning of the module is simple and accurate when using the precision flange diameter. Pneumatic supply is possible by manifolds or 

pipes/hoses. Pneumatic pressure is needed for unclamping ( min 8 bar/ 116 psi, max 12 bar/ 175 psi). For clamping process pneumatic pressure of min 5 bar / 75 psi, max 

6 bar / 90 psi is required briefly in order to achieve defined pull-in force. The installation clamping module is mechanically locked in the clamped position. The unique mechanical 

locking system results in virtually no vibration even with extensive machining forces. The pneumatic design has 2 connections: 1 x unclamping / 1 x clamping. 




Horizontal Rapid-Clamping Cylinder 




• For easy handling of heavy fixtures 

• Makes palletization very quick by hooking 

into a hole at the top and moving downwards 

• No searching for the holes 

• No damage to Zero-Point bore or pull studs 


Part Pull-In/Locking Holding Advance Motion, Hydr. 

Number Size Force up to kN / (lbs) Force kN / (lbs) Blow Out Suspension Piston kg 

303065 K20 20 / (4500) 55 / (12350) 2.1 

306217 K20 20 / (4500) 55 / (12350) Yes 2.1 

303073 K20 20 / (4500) 55 / (12350) Yes 2.1 

306233 K20 20 / (4500) 55 / (12350) Yes Yes 2.1 

303107 K40 40 / (9000) 105 / (23600) 5.2 

306258 K40 40 / (9000) 105 / (23600) Yes 5.2 

303115 K40 40 / (9000) 105 / (23600) Yes 5.2 

306274 K40 40 / (9000) 105 / (23600) Yes Yes 5.2 

Dimensions (mm) 

Part Number ØD ØDN ØD1 ØD2 H HA ØLK ØLK1 M M1 T T1 

303065 112 32 78 40 109 10 88 60 M6 M6 56.5 99 

306217 112 32 78 40 109 10 88 60 M6 M6 56.5 99 

303073 112 32 78 40 109 10 88 60 M6 M6 56.5 99 

306233 112 32 78 40 109 10 88 60 M6 M6 56.5 99 

303107 148 40 102 48 144 15 118 76 M8 M6 73 129 

306258 148 40 102 48 144 15 118 76 M8 M6 73 129 

303115 148 40 102 48 144 15 118 76 M8 M6 73 129 

306274 148 40 102 48 144 15 118 76 M8 M6 73 129 


Note: As standard, there is a manaul or hydraulic advance motion of the suspension piston. 

Release Mode 

Clamped Mode 

1.50

BALL LOCK Â® MOUNTING SYSTEM QUICK CHANGE ... - Jergens Inc.

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